Method of making forged compromise bars



May 10, 1932.

METH6D OF MAKING FORGED COMPROMISE .BARS

Filed y 5, 1927 2 Sheets-Sheet l w. BENDER ,857,582

h I M.

- INVENTOR. Ma alum BY M 11 M" A TTORNEY I May 10, 1932. w. BENDER'V 71,857,582

' 7 METHOD OF MAKING FORGED COMPROMISE BARS Filed May 1927 2Sheets-Sheet 2 I INVENTOR."

A TTORNEY latentedlviay n, was

fs rAT-Es PATENT caries wnmux BENDEB, or nowms oaovn, ILLINOIS, assranoa'ro nma'ronux ooze-h 'EORATION, OB NEW YORK, N. Y., A-CORPOBATION OF NEWYORK HETHDD F WGFQEGED CQMPROMISE BARS i I Y Application filed May 5,1927. Serial 170. 188,879.

both upper and lower fishing surfaces of the connector bar may be formedin one section, preferably the lower section. After the forgmgoperation, the fins caused thereby may be sheared off in a suitableshearin machine, and the bolt holes may be punche in a suitable punchingmachine. The bar may then a be allowed to cool slowl after which it maybe heat treated to give t e bar proper tern or to withstand the workingstresses to which it may be subjected in use.

Some of the advantages in making a bar in this way are the formation ofa bar hav- 7 ing sharpand abrupt offsets, which supports the railssubstantially at the ends thereof, so as to minimize the up and downmovement of the rail ends which causes the ends of the rails to bepounded by thewheels rolling thereon. According to the invention, thisis accomplished without undul weakening the bar, either by decreasing te cross section thereof or by setting up strains which affect thestrength of the bar. Furthermore, the provision of a die in which bothupper and ower fishing surfaces are formed by the same section thereofinsures accuracy 1n the formation of the fishing surfaces.

Various other features and advantages of the invention will be apparentfrom the following particular description and from an ins ction of theaccompanying drawings.

though the novel features which are believed to be characteristic ofthis invention will be pointed out with particularity in the claims apnded hereto, the invention itself, as to its ohiects and advantages, themode of its operation and the manner of its organization may be betterunderstood by referring to the following description takenin connewtionwith the accompanying drawings forma in a part thereof, in which ig. 1is a side elevation showing f pronnse angle bar according to theinvention applied to the inner or gage side of a pair 0 rails ofdifferent sections. Fig. 2 is a section on'the line 2-2 of Fi 1, takenthrough the larger end of the angle ar. Fig. 3 is a section similar toFig. 2, taken on the line 3-3 of Fig. 1, through the angle bar at thesmaller end. Fig. 4 is a section on the line 4-4 of'Fig. 1,. atsubstantially the middle of the angle bar showing the reenforcements.therein.

Fig. 5 represents the appearance of the billet after it has been roughforged in the roughing die.

Fig. 6 is a section through the forming die showing an an le bar formedinto shape.

Fig. 7 is a p an view of the lower section of the forming die.

Fig. 8 is a section through a combined shearing and punching machine.

Fi 9 is. a detail showing the male die mom ers used for punching thebolt holes.

In the following description and in the claims parts will be identifiedby specific names for convenience, but theyare intended to be as genericin their application to similar parts as the art will permit.

Referring now to the drawings and more particularly to Figs.'1 to 4, asingle compromise angle bar made according to the in vention is shownconnecting two rails of different section. Although only the inner orgage side angle bar is shown for the purpose of illustrating theinvention, it will be understood that the outer an le bar connecting therails on their outer si es ma also be made 90. according to theteachings o the invention. Each rail may be of a standard sha ecomprising a head, web and flange. T e rails may differ in one or moredimensions, such as height and width.

The angle bar comprises a large end 10 adapted to fit the fishingsection of the large rail 11, and a small and 12 adapted to fit thefishing section of the small rail 13. The large end, as shown in Fig. ismade up of a web 100 2 1,857,582 14, head and flange 16, the flangehaving Throughout the entire periphery of the die a depending rib 17which is provided for recess 29, a clearance space 31 is left whichstrengthening purposes; The upper surface, may be formed part in theupper section and 18 of the head is a fishing surface, and the part inthe lower section, to allow s ace for lower surface 19 of the flange isalso-a fishing the excess metal to be squeezed out. lightly 70 surface,these surfaces fitting the head and more metal is placed in the billetthan is nec flange of the rail, respectively. essary to make a finishedbar to insure the The small end 12 is'shaped similarly to the die moldto be completely filled. The clearlarge end, and has an upper fishingsurface ance space31 accommodates the excess metal 20 and a lowerfishing surface 21 adapted to which is squeezed out during forging. "l5fit the head and flange respectively of the It will be understood thatthe die sections small rail 13 as shown clearly. in Fig.3. are placed insuitable holders, the'lower sec- To take care of the difference insections tion 28 being placed uponthe base or table between the rails,the bar is provided with 32 of a suitable hammer or press, and the*"ofisetportions adjacentthe point where the upper section being placedin the movable rails meet. The'angle bar is oifset upwardpart 33 of thehammer or press in proper ly from the large.-.-to"the' small end totake, alignment with thelower section. care of the di'salignment of thefishing sur- \Vhen the billet is formed to arough ap faces of the rails.In the angle bar shown in the roughing die a proper-temperature n thehorizontal offset between the large and, should be used. A temperatureseveral hunsmall ends is practically nil, but it will be dred degreesbelow the melting point isgen-i "appreciated that, if necessary, the barmay erally sufficient. hen the billet is to be be ivenan appreciablehorizontal offs t in placed in the forming die, it may be reheatad itionto a vertical oifset.-.- ;.Th'e head 15 ed to a temperature sufficientlyhigh to cause 25 and web 14 is provided with a strengthening the metalto flow easily when subjected to projection 22 at the point where therails pressure in the die. meet, and the flange 16 is also provided withThe angle bar is further operated upon a projection 23 at this point, asshown clear-' before cooling by the apparatus shown in ly in Figs. 2, 3and 4. Figs. 8 and 9. The deviceshown in Figs. 30 The bar is providedwith bolt holes 2 1 8 and 9 is a combined shearing machine and throughthe web thereof, along the center punching machine. The shearing machinelines at the large and small ends and is boltwill first be described. Itcomprises a' lower ed to the rails by bolts 25 as is well undersection36 made up of a base 37 having a st od in the art. Spi e mat es 26 m y as chamber 38 in which the finished bar may 35 be provided in the flangeif desi d. drop. Positioned over the chamber is alower The shape of theangle bar is such that shearing member 39, havin an openingd l therails'receive support therefrom at subf h ha o that its e gs supportsthe v stantially the extreme ends thereof. The bar by the fin 40thereof, around the entire forging process makes this possible. Theoifperiphery of. the bar; j r QF y be made q e Sharp d b p The uppersection 41 of'the shearing rimwithout setting up undesirable strains inthe hi i d up f a it bl h ld 42, d metal and h bill at the Ofi'set y ban upper shearing member 43 shaped to fit trelgthened If desired y means0f the P the surface of the bar, and having shearing JeCtloIlS Shown.edges which co-operate with the shearing 45 T0 make an a g bar of thecharacter edges of the lower shearing member. It will above described abillet of the proper kind b d t d th t th upper d lower 9 Stet/1 y befirst rough forged a htions are properly aligned, and that the uping dieto a shape 27 somewhat as shown in per shearing member is moveddownwardly gthls l bemg 5ub$ mnt1any toward and into the lower shearingmember 50 tangular, and having a thick side and a thin t h -Off th fi thb th d i 11;

side. The modified billet 27 may then be i it receiving h b 1 p liacedin a forming die such as shown in Th hi hi comprises anup. 6 and I persection 45 and a lower section 46. The The forming die shown comprises a101 lower section 46 comprises the base 37 having 55 Section 28 made ofSultable matel'lll hfiwlng suitable recesses 48 and a plurality ofshearv a recess 29 shaped to form the rail side of i i l 49 i l f h b lt1 1 f the head and flange of the angle These nipples fit in the recessesin the base and to P fi necessary Q fi thereln- The and have openings 50therein and clearance pp Sec/Q1011 3O the 13 made to fit the spaces 51underneath. The nipples also have 30 lower section, and is shaped toform the other j ti ll 52 f proper h i ht, t 1 5 side of the web, headand flange f h ng tact and support the bar on the web thereof. r, Showncle ly 1n g- The 1 1 The upper section 45 com rises the holder sectioncooperates to place the necessary oif- 42 h i g a plunger mem ersuitably sesets in the angle bar, and also to form cured thereto. Theplunger member is made the necessary strengthening projections. up of anattaching bar 53 having a plurality of plungers 54 suitably securedthereto, these plungers piercin the web and passing into the holes 50 int e nipples, when the upper section moves downwardly.

The bar is then allowed to cool slowly, and if desired, after cooling,the spike notches 26, are punched in the flange. After the bar coolssufficiently, it may be subjected to suitable heat treatment tostrengthen the bar, andut it; in the best condition for with.- stan inuse. i

Thus, it will be seen that the-improved g the stresses which it mustWithstand I which" comprises, forming a billet of steel to a roughshape, forging the rough shape in a forming die to a finished shapehaving a projecting fin, thereb forming t e fishing surfaces on the weban flange in one section of the forming die, removing the fin, unchingbolt holes inthe web, cooling t e bar slowly, and then heat-treatingsaid bar.v

-' testimony whereof, I have hereunto set my. l andnncl seal.

. process produces an angle bar which has 0tf set portions which arequite shear and abrupt, giving support to the rails su Stan-" tially atthe ends thereof. The drop forging j 1 operation places these ofi'setsin the bar andthereof in such manner to prevent relative verticalmovement of the rails.

While certain novel features of the inven tion are shown and describedand are pointed out in the annexed claims, it will be understood thatvarious omissions, substitutions and changes in the process andapparatus above disclosed may be made by those skilled in the artwithout departing from the spirit of the invention.

What is claimed is: 1. The method of making a angle bar having a head,web and flange, offset and strengthening projections, which comprises,forging a billet of steel to a rough compromise v shape in a roughingdie, forging the rough shape in a forming die to a finished shape havinga projecting fin, thereby forming the fishing surfaces on the head andflange in one section of the forming die, shearing off the fin beforecooling in a shearing die, punching bolt holes in the web before cooling, cooling the bar slowly, punching spike notches in the flange, andthen heat-treating said bar. r

2. The method of makin a compromise angle bar having a web, ange andoffset which comprises, forging a suitable billet in a forming die to afinished shape having a projecting fin, removing the fin before cooling,punching bolt holes in the web before cooling, cooling the bar slowly,and then heat-treating said bar.

3. The method of making a compromise angle bar having a web, flange andoffset WILLIAM n'nunnn.

